Phytase formulation

Abstract

A liquid enzyme formulation, an enzyme granule formulation, methods for manufacturing enzyme granules using a fluid bed dryer, wherein the enzyme granules are thermostable without the need for a thermostable coating is provided. The enzyme granules are phytase granules used in the manufacturing of an animal feed, wherein the phytase granule is thermostable without the need for a thermostable coating and the phytase retains about 63% to about 134% of its activity after pelleting at 80 C.

Claims

1. A liquid enzyme formulation comprising: (a) a phytase at a concentration of 5,000 to 50,000 unit/ml of the liquid enzyme formulation; (b) a buffer, at a concentration of 0.5%-2.5% w/v, wherein the buffer is selected from the group consisting of: a sodium citrate, potassium citrate, citric acid, sodium acetate, acetic acid, sodium phosphate, potassium phosphate and any combination thereof; (c) a stabilizer, at a concentration of 1%-40% w/v, wherein the stabilizer is selected from the group consisting of: a sucrose, a sorbitol, a mannitol, a glycerol, a trehalose, a sodium chloride, a sodium sulphate, or any combination thereof; and, (d) an anti-microbial, at a concentration of 0.05%-0.40% w/v, wherein the anti-microbial is selected from the group consisting of: a potassium sorbate, sodium sorbate, a sorbic acid, a sodium benzoate, a benzoic acid, a methyl paraben, a calcium propionate, a sodium propionate, an ammonium propionate, a propionic acid, or any combination thereof, wherein the phytase retains at least 63% of its activity at a temperature of 80 C.

2. The liquid enzyme formulation of claim 1, wherein (a) the buffer has a pH in a range from 4.5 to about 5.50, (b) the stabilizer is a combination of at least two stabilizers, (c) the stabilizer is at a concentration between 5% to 30%, or (d) the anti-microbial is a combination of at least two anti-microbials.

3. The liquid enzyme formulation of claim 1, wherein: (a) the phytase has a concentration of 5,000 to 20,000 unit/ml, (b) sodium chloride at a concentration of 1% to 20% w/v, (c) sorbitol at a concentration of 2% to 20% w/v, (d) glycerol at a concentration of 2% to 40% w/v, (e) potassium sorbate at a concentration of 0.05% to 0.4% w/v, (f) sodium benzoate at a concentration of 0.05% to 0.4% w/v, (g) methyl paraben at a concentration of 0.05% to 0.4% w/v, or (g) a propionate salt at a concentration of 0.05% to 0.4% w/v, wherein the propionate salt is selected from the group consisting of calcium propionate, sodium propionate, ammonium propionate, and any combination thereof.

4. The liquid enzyme formulation of claim 3, wherein: (a) the phytase has a concentration of 10,000 unit/ml, (b) sodium chloride at a concentration of 15% w/v, (c) sorbitol at a concentration of 20% w/v, (d) glycerol at a concentration of 20% w/v, (e) potassium sorbate at a concentration of 0.20% w/v, (f) sodium benzoate at a concentration of 0.20% w/v, (g) methyl paraben at a concentration of 0.20% w/v, or (g) a propionate salt at a concentration of 0.20%, wherein the propionate salt is selected from the group consisting of calcium propionate, sodium propionate, ammonium propionate, and any combination thereof.

5. The liquid enzyme formulation of claim 1, wherein: (a) the phytase has a concentration of 11,000 to 12,000 unit/ml, (b) sodium chloride at a concentration of 15% w/v, (c) sorbitol at a concentration of 4% w/v, (d) sodium citrate at a concentration of 50 mM, (e) potassium sorbate at a concentration of 0.2% w/v, (f) sodium benzoate at a concentration of 0.1% w/v, or (g) sodium propionate at a concentration of 0.1%.

6. The liquid enzyme formulation of claim 5, wherein the stabilizer further comprises sorbitol at a concentration of 4% w/v and/or sucrose at a concentration of 6% w/v.

7. The liquid enzyme formulation of claim 1, wherein: (a) the phytase has a concentration of 44,000 to 48,000 unit/ml, (b) sucrose at a concentration of 20% w/v, (c) sodium chloride at a concentration of 1% w/v, (d) sodium citrate at a concentration of 50 mM, (e) sodium benzoate at a concentration of 0.1% w/v, (f) potassium sorbate at a concentration of 0.4% w/v, or (g) sodium propionate at a concentration of 0.4%.

8. The liquid enzyme formulation of claim 7, wherein the stabilizer further comprises sorbitol at a concentration of 2% to 40% w/v and/or sucrose at a concentration of 20% w/v.

9. The liquid enzyme formulation of claim 1, wherein said liquid enzyme formulation comprises at least two of said anti-microbials.

10. The liquid enzyme formulation of claim 1, wherein the liquid enzyme formulation is combined with an animal feed.

11. The liquid enzyme formulation of claim 10, wherein the animal feed is a dry animal feed.

Description

DETAILED DESCRIPTION

(1) An enzyme as used herein refers to any enzyme that can be used as an additive for animal feed. For example, enzymes useful in the present invention include, but are not limited to: a phytase, lactase, lipase, protease, catalase, xylanase, cellulase, glucanase, mannanase, amylase, amidase, epoxide hydrolase, esterase, phospholipase, transaminase, amine oxidase, cellobiohydrolase, ammonia lyase, or any combination thereof.

(2) A phytase is an enzyme that catalyzes the removal of one or more phosphate groups from a phytate substrate. In another embodiment, a phytase is a phosphoric monoester hydrolase enzyme that catalyzes hydrolysis of phytic acid (myo-inositol-hexakisphosphate) to phosphate and myo-inositol having fewer than six phosphate groups. According to the recommendations of the Nomenclature Committee of the International Union of Biochemistry and Molecular Biology (IUBMB) and Bairoch A., The ENZYME database in 2000, Nucleic Acids Res 28:304-305(2000), a phytase may be described in a variety of names and identifying numbers. In another embodiment, a phytase is characterized as having Enzyme Commission (EC) number EC 3.1.3.8, and are also referred to as: 1-phytase; myo-inositol-hexakisphosphate 3-phosphohydrolase; phytate 1-phosphatase; phytate 3-phosphatase; or phytate 6-phosphatase. In another embodiment, a phytase is characterized as EC 3.1.3.26, also referred to as: 4-phytase; 6-phytase (name based on 1L-numbering system and not 1D-numbering); or phytate 6-phosphatase. In another embodiment, a phytase is characterized as EC 3.1.3.72, also referred to as 5-phytase. In another embodiment, a phytase is a histidine acid phosphatase (HAP); a -propeller phytase; purple acid phosphatase (PAP); and protein tyrosine phosphatase (PTPs). In some embodiments, a phytase is described using nomenclature know in the art.

(3) An inositol phosphatase is an enzyme that catalyzes the removal of one or more phosphate groups from an inositol phosphate molecule.

(4) A phytate or phytic acid is myo-inositol hexaphosphate. It is the fully-phosphorylated form of inositol phosphate.

(5) An inositol phosphate is myo-inositol that is phosphorylated at one or more of its hydroxyl positions.

(6) A cellulase is an enzyme that catalyzes the hydrolysis of a polymeric carbohydrate compound such as cellulose, glucomannan, mannan, glucan, and xyloglucan, for example.

(7) A xylanase is an enzyme that catalyzes the degradation of the linear polysaccharide beta-1,4-xylan into xylose.

(8) A glucanase is an enzyme that catalyzes the degradation of glucans comprising glucose sub-units. Examples of glucanases include alpha-1,4-glucanases, alpha-1,6 glucanases, pullulanases, beta-1,3,-glucanases, beta-1,4-glucanases, and beta-1,6-glucanases.

(9) A mannanase is an enzyme that catalyzes the degradation of mannose polysaccharide polymers.

(10) An amylase is an enzyme that catalyzes the hydrolysis of 1,4-alpha-D-glucosidic linkages to degrade polysaccharides, oligosaccharides, and/or starch into glucose subunits.

(11) The term comprising as used herein is synonymous with including, containing, or characterized by, and is inclusive or open-ended and does not exclude additional, unrecited elements or method steps.

(12) An enzyme is thermostable if it retains a substantial amount of its activity after a high temperature treatment of at least about 65 C. to about 95 C.; or at a temperature greater than 95 C.

(13) In some embodiments, the thermostable enzyme retains at least: 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, or 100% of its activity after a pelletization process. In an embodiment, the pelletization process is conduct at a temperature of at least: 75 C., 80 C., 85 C., 88 C., 90 C., or 93 C.

(14) A combination of enzymes is any combination of enzymes that may be used as additives for an animal feed. Examples of such combinations of enzymes are set forth in Table 1.

(15) TABLE-US-00001 TABLE 1 Combination of Enzymes Phytase Xylanase Glucanase Amylase Protease 1 X X 2 X X 3 X X 4 X X 5 X X X 6 X X X 7 X X X 8 X X X 9 X X X 10 X X X 11 X X X X 12 X X X X 13 X X 14 X X 15 16 X X 17 X X 18 X X 19 X X 20 X X X 21 X X X X X

(16) As used herein liquid enzyme formulation is a composition comprising an enzyme, a buffer, a stabilizer, and an anti-microbial.

(17) In one embodiment, a liquid enzyme formulation comprises an enzyme, wherein the enzyme is a phytase, a cellulase, a lactase, a lipase, a protease, a catalase, a xylanase, a beta-glucanase, a mannanase, an amylase, an amidase, an epoxide hydrolase, an esterase, a phospholipase, a transaminase, an amine oxidase, a cellobiohydrolase, an ammonia lyase, or any combination thereof.

(18) In one embodiment, a liquid enzyme formulation comprises a buffer includes, but is not limited to sodium citrate, potassium citrate, citric acid, sodium acetate, acetic acid, sodium phosphate, potassium phosphate and any combination thereof.

(19) In one embodiment, a liquid enzyme formulation comprises a stabilizer, wherein the stabilizer is a sodium chloride, a sorbitol, a glycerol, a sucrose, a mannitol, a trehalose, or any combination thereof. In another embodiment, a liquid enzyme formulation may include two stabilizers.

(20) In one embodiment, a liquid enzyme formulation comprises an anti-microbials, wherein the anti-microbial is a potassium sorbate; a sodium sorbate, a sorbic acid; a sodium benzoate; a benzoic acid a calcium propionate, a sodium propionate, an ammonium propionate; a propionic acid or any combination thereof.

(21) In one embodiment, the liquid enzyme formulation is set forth in Table 2:

(22) TABLE-US-00002 Concentration Category Options Ingredient (% w/v) Enzyme phytase 10,000 units/ml (5,000-20,000 unit/ml) Buffer sodium citrate, 1.25% pH 5.0 (4.5-5.5) (0.5-2.5%) Stabilizer 1 sodium chloride 15% (1-20%) 2 sorbitol 20% (2-40%) 3 glycerol 20% (2-40%) 4 sucrose 20% (2-40%) Anti- 1 potassium sorbate 0.20% (0.05-0.40%) microbial 2 sodium benzoate 0.20% (0.05-0.40%) 3 methyl paraben 0.20% (0.05-0.40%) 4 calcium/sodium/ 0.20% (0.05-0.40%) ammonium propionate

(23) In one embodiment, the liquid enzyme formulation is a liquid product, wherein the liquid product is applied to the post pelleting. In another embodiment, the liquid product is an enzyme, sodium chloride, sorbitol, sodium citrate, potassium sorbate, and sodium benzoate. In another embodiment, the liquid product is a composition having a Phytase having 11,000-12,000 unit/g, a sodium chloride 15%, a sorbitol 4%, a sodium citrate 50 mM, a potassium sorbate 0.2%, a sodium benzoate 0.1%, and a sodium propionate 0.1% (all % are w/v %). In another embodiment, the liquid product is a composition having a Phytase having 11,000-12,000 unit/g, a sodium chloride 15%, a sucrose 6%, a sodium citrate 50 mM, a potassium sorbate 0.2%, a sodium benzoate 0.1%, sodium propionate 0.1% (all % are w/v %).

(24) In one embodiment, the liquid enzyme formulation is a liquid concentrate, wherein the liquid concentrate is added to the feed mash prior to the pelleting process. In one embodiment, the liquid concentrate is an enzyme, and sucrose, and sodium chloride, and sodium citrate and potassium sorbate, sodium benzoate, and sodium propionate. In another embodiment the liquid concentrate is a composition comprising: a Phytase having 44,000-48,000 unit/g, 20% sucrose, 1% NaCl, 50 mM sodium citrate, pH 5.1, 0.1% sodium benzoate, 0.4% potassium sorbate, 0.4% sodium propionate. In another embodiment the liquid concentrate is a composition comprising: a Phytase having 44,000-48,000 unit/g, 2%-40% sorbitol, 1% NaCl, 50 mM sodium citrate, a pH 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, or 5.5, 0.1% sodium benzoate, 0.4% potassium sorbate, 0.4% sodium propionate. In another embodiment, the liquid concentrate is not the final product, but is an intermediate composition or formulation that is later used for the production of a liquid product a granulated dry product.

(25) As used herein a granulated enzyme formulation is a composition comprising: a carrier; a primary solution comprising an enzyme, a buffer, a stabilizer, a binding agent, a plasticizer, an anti-microbial, or any combination thereof. In another embodiment, a granulated enzyme formulation is a composition comprising: a carrier; a primary solution comprising an enzyme, a buffer, a stabilizer, a binding agent, a plasticizer, an anti-microbial, and a secondary solution comprising an enhancer, a plasticizer, or any combination thereof. In one embodiment, a granulated enzyme formulation is thermostable without the need for the enzyme granule to have a protective coating. In another embodiment, the granulated product is an enzyme, sucrose, sodium chloride, sodium citrate, potassium sorbate, sodium benzoate, sodium propionate, guar gum, wheat flour.

(26) In one embodiment, the primary solution is a liquid enzyme formulation. In another embodiment, the liquid enzyme formulation is a liquid product or a liquid concentrate.

(27) In one embodiment, a granulated enzyme formulation comprises a carrier, wherein the carrier is a flour. In another embodiment, the carrier is a starch. In an embodiment, the flour is a wheat flour. In another embodiment, the wheat flour is bleached wheat flour. In another embodiment, the carrier is a wheat flour and a maltodextrin. In another embodiment, the carrier is a wheat flour and a pre-gelatinized starch. In another embodiment, the maltodextrin or pre-gelatinized starch is used as a dry mixture with flour. In another embodiment, the flour is a wheat flour, or bleached flour. In an embodiment, the maltodextrin or pre-gelatinized starch is used as a dry mixture. In an embodiment, the wheat flour and kaolin is a dry mixture.

(28) In one embodiment, a granulated enzyme formulation comprises an enzyme, wherein the enzyme is a phytase, a cellulase, a lactase, a lipase, a protease, a catalase, a xylanase, a beta-glucanase, a mannanase, an amylase, an amidase, an epoxide hydrolase, an esterase, a phospholipase, a transaminase, an amine oxidase, a cellobiohydrolase, an ammonia lyase, or any combination thereof.

(29) In one embodiment, a granulated enzyme formulation comprises a buffer, wherein the buffer is a sodium citrate, potassium citrate, citric acid, sodium acetate, acetic acid, sodium phosphate, potassium phosphate and any combination thereof.

(30) In one embodiment, a granulated enzyme formulation comprises a stabilizer, wherein the stabilizer is a sucrose, a sodium chloride, a sorbitol, a glycerol, a sucrose, a mannitol, a trehalose, kaolin, aluminum silicate, magnesium silicate or any combination thereof.

(31) In one embodiment, a granulated enzyme formulation comprises a binding agent, wherein the binding agent is a guar gum, a xanthan, a sodium algenate, a locust bean gum, a carrageenan gum, a pre-gelatinized modified starch, a maltodextrin, gelatin, methyl cellulase, hydroxypropyl cellulase, hydroxypropyl methyl cellulase, carboxymethyl cellulase, or any combination thereof. In another embodiment, the natural gums may be used individually or as a combination of at least two gums. In another embodiment, starch or maltodextrin are used in combination with guar gum. In another embodiment, starch or maltodextrin also act as a stabilizer.

(32) In one embodiment, a granulated enzyme formulation comprises a plasticizer, wherein the plasticizer is selected from a group consisting of: a glycerol, polyethylene glycol, triethyl citrate, triacetin, acetyl triethylcitrate.

(33) In one embodiment, a granulated enzyme formulation comprises an anti-micorbial, wherein the anti-micorbial is a potassium sorbate, sodium sorbate, sorbic acid, propionic acid, sodium benzoate, benzoic acidsodium propionate, calcium propionate, ammonium propionate, methyl paraben, or any combination thereof. In another embodiment, at least two anti-micoribals are used in the granulated enzyme formulation.

(34) In one embodiment, a granulated enzyme formulation comprises a secondary granulation solution, wherein the secondary granulation solution is a composition comprising a granule enhancer and a plasticizer. In another embodiment, the secondary granulation solution enhances the granule size, creates grater variability, or both. In another embodiment, the granule size is any numerical mesh size between the range from about 12 mesh to about 100 mesh size. In another embodiment, the granule size is any numerical mesh size between the range between from about 20 mesh to about 80 mesh. In another embodiment, the granule size is any numerical mesh size between the range from about 30 mesh to about 60 mesh.

(35) In one embodiment, a granulated enzyme formulation comprises a granule enhancer, wherein the granule enhancer is pre-gelatinized modified starch, maltodextrin, sodium algenate, carregeenan with CaCl2, carregeenan without CaCl2, guar gum with sodium borate, guar gum without sodium borate, gelatin; methyl celluloase; hydroxypropyl cellulose; hydroxypropyl methyl celluloase; carboxymethyl celluloase; sodium chloride; sodium sulphate; kaolin; aluminum silicate, magnesium silicate, and any combination thereof. In another embodiment, the enhancer is an optional addition to the granulated enzyme formulation. In another embodiment, the natural gum and ion combination will cross link the gum into protective gel; however, if the gum is already used as binding agent, then the addition of ion alone will suffice without the addition of extra gum.

(36) In one embodiment, a granulated enzyme formulation comprises a plasticizer, wherein the plasticizer is a glycerol. In another embodiment, glycerol may be used when pre-gelatinized modified starch is used.

(37) In one embodiment, a granulated enzyme formulation further comprising a flow aid or lubricant, wherein the flowing aid is selected from a group consisting of: a silicon dioxide, a magnesium stearate, a kaolin, a talc, diatomaceous earth, or any combination thereof. In another embodiment, the addition of a granulated enzyme formulation is a flowing aid or lubricant is optional. In another embodiment, the flowing aid or lubricant is a dry blend post drying. In another embodiment, the flowing aid or lubricant is added as a suspension in the secondary granulation solution. In another embodiment, the granulated dry product is a composition comprising: a Phytase having 11,000-12,000 unit/g, a sucrose 4.5%, a sodium citrate 0.3%, a potassium sorbate 0.1%, sodium benzoate 0.1%, sodium propionate 0.1%, guar gum 0-0.25%, and a wheat flour 95% (all % are w/w %).

(38) In one embodiment, a granulated enzyme formulation is set forth in Table 3:

(39) TABLE-US-00003 Concentration Amount per in liquid feed kg of dried Material Category Options Ingredient (% w/v) product (g) Carrier Carrier 1 wheat flour 850-950 g 2 wheat flour 700-800 g maltodextrin or pre-gelatinized starch 100-200 g Enzyme Enzyme phytase 40,000 unit/ml 10,000 unit/g solution/ (10,00-50,000 (5,000-20,000 Primary unit/ml) unit/g) granulation Buffer sodium citrate, pH 5.0 (4.5-5.5) 1% (0.5-2.0%) 3 g (1.5-6.0 g) solution Stabilizer 1 sucrose 20% (10-30%) 50 g (25-100 g) 2 sodium chloride, or sodium sulphate 1% (0.5-10%) 2 g (1-20 g) Binding 1 guar gum 0.5% (0.2-1%) 1.25 g agent (0.5-2.5 g) 2 xanthan, sodium algenate, locust bean 0.5% (0.2-1%) 1.25 g gum, or carrageenan (0.5-2.5 g) 3 pre-gelatinized modified starch (corn) 5% (2-10%) 12.5 g (5-25 g) 4 maltodextrin 10% (5-20%) 25 g (12.5-50 g) Plasticizer glycerol 0.5% (0.2-1%) 1.25 g (0.5-2.5 g) Anti- 1 potassium sorbate 0.4% 1.0 g microbial 2 sodium benzoate 0.4% 1.0 g 3 sodium/calcium/ammonium 0.4% 1.0 g propionate 4 methyl paraben 0.10% 0.25 g Secondary Granule 1 pre-gelatinized modified starch (corn) 12% (10-15%) 25 g granulation enhancer (5-50 g) solution 2 maltodextrin 25% (10-50%) 50 g (25 g-100 g) 3 sodium algenate or carrageenan 5% (2-10%) 10 g with CaCl2 (5 g-25 g) 4 guar gum with sodium borate 0.5% (0.2-1.0%) 1.25 g (0.5-2.5 g) 5 sodium chloride, or sodium sulphate 20% (10-30%) 40 g (20 g-80 g) 6 Kaolin 10% (1-20%) 20 g (10-40 g) Plasticizer glycerol 1.2% (0.2-1%) 2.5 g (1-5 g) Flowing Flowing 1 silicon dioxide 10 g (1-20 g) aid/lubricant aid/lubricant 2 magnesium stearate 10 g (2.5-15 g) 3 kaolin 20 g (5-50 g) 4 talc 30 g (10-100 g)

(40) All numbers expressing quantities of ingredients, reaction conditions, and so forth used in the specification are to be understood as being modified in all instances by the term about. Accordingly, unless indicated to the contrary, the numerical parameters set forth herein are approximations that may vary depending upon the desired properties sought to be obtained. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of any claims in any application claiming priority to the present application, each numerical parameter should be construed in light of the number of significant digits and ordinary rounding approaches. In addition, the numerical ranges disclosed in this application are inclusive and disclose all of the numerical digits within a range. For example a range of pH from 4.5 to 5.5 includes a pH of 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, and 5.5.

(41) The above description discloses several methods and materials of the present invention. This invention is susceptible to modifications in the methods and materials, as well as alterations in the fabrication methods and equipment. Such modifications will become apparent to those skilled in the art from a consideration of this disclosure or practice of the invention disclosed herein. Consequently, it is not intended that this invention be limited to the specific embodiments disclosed herein, but that it cover all modifications and alternatives coming within the true scope and spirit of the invention.

(42) All references cited herein, including but not limited to published and unpublished applications, patents, and literature references, are incorporated herein by reference in their entirety and are hereby made a part of this specification. To the extent publications and patents or patent applications incorporated by reference contradict the disclosure contained in the specification, the specification is intended to supersede and/or take precedence over any such contradictory material.

EXAMPLES

Example 1

Comparative Example of Non-Granulated Phytase

(43) Formulation 1A liquid concentrate phytase formulation containing 10% sodium chloride and 10% sorbitol was dried by lyophilization. The dried enzyme powder was then diluted by mixing with calcium carbonate and rice hulls to form a rice hull enzyme product.

(44) Formulation 2A liquid concentrate phytase formulation containing 10% sodium chloride and 10% sorbitol was soaked on the rice hulls. The resulting wet blend was dried by lyophilization. The dried material was diluted by mixing with calcium carbonate to form a rice hull enzyme product.

(45) Pelleting TrialsThe rice hull enzyme product was blended with poultry feed mash at 25-100 ppm concentration, and pelleted in a California Pellet Mill at various controlled temperatures in the range of 75 C. to 93 C. The mash mixture was first conditioned by direct steam at said temperature for 15 seconds, and then pelleted through the pelleting press. The pellets were subsequently dried.

(46) Enzyme Stability DeterminationThe starting mash and finished pellets (which were milled down to mash) were extracted in a Tris buffer. Phytase activities in the extracts were determined by a modified AOAC method. The modified AOAC method is the AOAC buffer comprising distilled water plus 0.01% Tween 20 (GIZZI, J. of AOAC International, Vol. 91, No. 2, 2008) and was modified to a composition comprising: 50 mM Tris pH 8.0, 0.01% Tween20, 10 mM CaCl.sub.2.

(47) The percent recovery of the enzyme activity of pelleted product at each temperature was compared to that of the starting mash. The results are shown in Table 4.

(48) TABLE-US-00004 TABLE 4 Residual Phytase activities (%) in poultry feed after pelleting at different conditioning temperatures Sample # 75 C. 80 C. 85 C. 88 C. 90 C. 93 C. Formulation 1 70% 63% 55% 49% 16% 6% Formulation 2 63% 64% 51% 43% 27% 13%

(49) The results show that phytase activity extracted from the pelleted feed was lower at high conditioning temperatures for both formulation 1 and formulation 2.

Example 2

(50) Formulation 3250 g of rice hulls was loaded in a GEA Aeromatic-Fielder Strea-1 fluid bed granulator; 50 ml of a liquid concentrate phytase formulation containing 10% sorbitol and 10% sodium chloride was sprayed onto the rice hulls through a top spray two-fluid nozzle. The following fluid bed settings were used: 55 C. inlet air temperature, 5 ml/min spray rate, 1 bar atomizing pressure, 0.8 mm spray nozzle. The rice hull enzyme product was dried after the enzyme spray.

(51) Formulation 4200 g of rice hulls was loaded in a GEA Aeromatic-Fielder Strea-1 fluid bed granulator; 100 ml of a liquid concentrate phytase formulation containing 20% sucrose was sprayed onto the rice hulls through a top spray two-fluid nozzle. The fluid bed settings were the same as Formulation 3 and were used to form a rice hull enzyme product.

(52) Formulation 5200 g of wheat flour was loaded in a GEA Aeromatic-Fielder Strea-1 fluid bed granulator; 100 ml of a liquid concentrate phytase formulation containing 20% sucrose and 7% pre-gelatinized starch was sprayed onto the wheat flour through a top spray two-fluid nozzle. The following fluid bed settings were used: 50 C. inlet air temperature, 10-15 ml/min spray rate, 1.5-2 bar atomizing pressure, 0.8 mm spray nozzle. The wheat flour and enzyme product was dried after the enzyme spray to form phytase granules.

(53) Pelleting Trials and Enzyme Stability Determination were the same as in Example 1. The results are shown in Table 5.

(54) TABLE-US-00005 TABLE 5 Residual Phytase activities (%) in poultry feed after pelleting at different conditioning temperatures Sample # 75 C. 80 C. 85 C. 88 C. 90 C. 93 C. Formulation 3 67% 70% 80% 56% 29% 9% Formulation 4 72% 75% 58% 56% 36% 17% Formulation 5 95% 89% 93% 79% 77% 38%

(55) Rice hulls were used as carrier in Formulations 3 & 4. The rice hulls were not finely milled and not very absorbent; in addition, no binder was used in these formulations. As a result, no effective granulation was seen in the rice hull enzyme products. The thermal stability for both formulations was relatively low at high conditioning temperatures when compared to Formulation 5. Switching the stabilizer from sodium chloride and sorbitol to sucrose improved thermostability of the phytase. However, when the carrier was switched from rice hulls to finely milled wheat flour in combination with the use of a pre-gelatinized starch as binder as in formulation 5. The wheat flour enzyme product was granulated, and the thermal stability of the phytase extracted from an animal feed pellet improved across all temperatures, especially at 90 C.

Example 3

(56) Formulation 63 kg of wheat flour was loaded in a Vector VFC-Lab 3 fluid bed granulator; 1.6 kg of liquid concentrate phytase formulation containing 20% sucrose and 0.5% guar gum was sprayed onto the wheat flour through a top spray two-fluid nozzle. The fluid bed settings were 1.2 mm nozzle diameter, 20 psi atomizing pressure, 50-55 C. inlet air temperature, 23-27 C. product temperature, 25-50 g/min pray rate during spray; 70-80 C. inlet air temperature during drying, dried to 45 C. end product temperature to form phytase granules.

(57) Formulation 73 kg of wheat flour was loaded in a Vector VFC-Lab 3 fluid bed granulator; 1.6 kg of liquid concentrate phytase formulation containing 20% sucrose, 10% maltodextrin and 0.5% guar gum was sprayed onto the wheat flour through a top spray two-fluid nozzle. The fluid bed settings were 1.2 mm nozzle diameter, 20 psi atomizing pressure, 50 C. inlet air temperature, 23-29 C. product temperature, 25-50 g/min pray rate during spray; 70-80 C. inlet air temperature during drying, dried to 45 C. end product temperature to form phytase granules.

(58) Pelleting Trials and Enzyme Stability Determination were the same as in Example 1. The results are shown in Table 6. All residual activities were normalized to 75 C. stability of the same sample.

(59) TABLE-US-00006 TABLE 6 Residual Phytase activities (%) in poultry feed after pelleting at different conditioning temperatures Sample # 75 C. 88 C. 90 C. 93 C. Formulation 3 100% 31% 9% Formulation 6 100% 92% 35% 5% Formulation 7 100% 76% 40% 4%

(60) Formulation 3 was the same sample from Example 2, and it was used as a control in this experiment. The thermal stability for formulation 3 is lower here than the value in Example 2, probably due to harsher pelleting conditions in this trial. Both Formulations 6 and 7 resulted in phytase granules that improved thermal stability of the phytase when extracted from a pelleted animal feed.

(61) Additional Pelleting Trialsto confirm the improvement in thermal stability, the phytase granules produced from the two samples (Formulation 6 and 7) were subjected to additional pelleting trial using a different California Pellet Mill. The duration for steam conditioning was 40 seconds, which is significantly longer than the previous pelleting trials. The results are shown in Table 7. All residual phytase activities were normalized to 75 C. stability of the same sample.

(62) TABLE-US-00007 TABLE 7 Residual Phytase activities (%) in poultry feed after pelleting at different conditioning temperatures. Sample # 75 C. 85 C. 90 C. 92 C. Formulation 6 100% 82% 66% 12% Formulation 7 100% 94% 50% 8%

(63) The results confirmed that even under prolonged steam conditioning, both phytase granules from Formulations 6 and 7 provided high phytase activity for phytase extracted from animal feed pellets generated at high pelleting temperature.

Example 4

(64) Formulation 83 kg of wheat flour was loaded in a Vector VFC-Lab 3 fluid bed granulator; 1.6 kg of liquid concentrate phytase formulation containing 20% sucrose, 10% kaolin and 0.5% guar gum was sprayed onto the wheat flour through a top spray two-fluid nozzle. The fluid bed settings were 1.2 mm nozzle diameter, 20 psi atomizing pressure, 50 C. inlet air temperature, 22-30 C. product temperature, 25-50 g/min pray rate during spray; 70-80 C. inlet air temperature during drying, dried to 45 C. end product temperature to form phytase granules.

(65) Formulation 93 kg of wheat flour was loaded in a Vector VFC-Lab 3 fluid bed granulator; 1.6 kg of liquid concentrate phytase formulation containing 20% sucrose, 10% maltodextrin, 5% kaolin and 0.5% guar gum was sprayed onto the wheat flour through a top spray two-fluid nozzle. The fluid bed settings were the same as in Formulation 8 to form phytase granules.

(66) Formulation 102 kg of wheat flour was loaded in a Vector VFC-Lab 3 fluid bed granulator; 1 kg of liquid concentrate phytase formulation containing 20% sucrose and 0.5% guar gum was sprayed onto the wheat flour through a top spray two-fluid nozzle; 1 kg of secondary granulation solution was then sprayed containing 10% modified starch, 10% kaolin and 1% glycerol. The fluid bed settings during enzyme spray were the same as in Formulation 8; during secondary granulation solution spray, the spray rate was 17-18 g/min, inlet air temperature was 60 C., and the product temperature was 30-31 C.; during drying, inlet air temperature was 70-80 C. to form phytase granules.

(67) Pelleting Trials and Enzyme Stability Determination were the same as in Example 1 and the results are shown in Table 8.

(68) TABLE-US-00008 TABLE 8 Residual Phytase activities (%) in poultry feed after pelleting at different conditioning temperatures Sample # 80 C. 85 C. 88 C. 90 C. 93 C. Formulation 8 74% 61% 79% 52% 20% Formulation 9 132% 71% 68% 58% 25% Formulation 10 104% 92% 79% 74% 28%

(69) The results showed that the inclusion of kaolin in the secondary granulation solution spray led to increased phytase thermal stability; and the use of a secondary granulation solution further enhanced the phytase thermal stability of the phytase extracted from the animal feed pellet.

Example 5

(70) Formulation 113 kg of wheat flour was loaded in a Vector VFC-Lab 3 fluid bed granulator; 1.3 kg of liquid concentrate phytase formulation containing 20% sucrose and 0.5% guar gum was sprayed onto the wheat flour through a top spray two-fluid nozzle. The fluid bed settings were 1.2 mm nozzle diameter, 20 psi atomizing pressure, 50 C. inlet air temperature, 22-29 C. product temperature, 25-50 g/min pray rate during spray; 70-80 C. inlet air temperature during drying, dried to 45 C. end product temperature to form phytase granules.

(71) Formulation 124.6 kg of wheat flour was loaded in a 5-kg scale customized fluid bed granulator; 1.25 kg of liquid concentrate phytase formulation containing 20% sucrose and 0.5% guar gum was sprayed onto the wheat flour through a top spray two-fluid nozzle; 1 kg of secondary granulation solution containing 0.5% guar gum only was then sprayed. The fluid bed settings were 60-80 C. inlet air temperature, 28-36 C. product temperature and 40 g/min spray rate to form phytase granules.

(72) Pelleting Trials and Enzyme Stability Determination were the same as in Example 1 and the results are shown in Table 9.

(73) TABLE-US-00009 TABLE 9 Residual Phytase activities (%) in poultry feed after pelleting at different conditioning temperatures Sample # 75 C. 80 C. 85 C. 88 C. 90 C. 93 C. Formulation 11 93% 111% 76% 113% 57% 38% Formulation 12 108% 108% 107% 129% 91% 73%

(74) The results showed that both samples had improved phytase thermal stability; and the use of a secondary granulation solution further enhanced the thermal stability of the the phytase extracted from an animal feed pellet generated at high pelleting temperatures.

Example 6

(75) Most thermally stable feed enzymes currently commercially available rely on thermal protective coating. Some of these coatings have been shown to inadvertently delay the enzyme release into the solution, which lead to reduced enzyme efficacy. Therefore, the time release profile of Phytase activity from the granulated product of the current invention was examined.

(76) One hundred milligrams of granulated Phytase from Formulation 12 was mixed with 400 ul of 100 mM sodium acetate buffer at pH 5.5. The mixture was agitated for up to 60 minutes. At designated time point, an aliquot was removed and centrifuged. Phytase activity in the clear supernatant was assayed. The results are shown in Table 10.

(77) TABLE-US-00010 TABLE 10 Time Release Profile of Phytase Activity Time (minutes) 2.5 5 7.5 10 15 20 Formulation 12 94% 100% 100% 100% 100% 100%

(78) The results show that Phytase became soluble in very short amount of time. On the other hand, some commercially available thermal coated Phytase granules displayed significant delay in releasing the enzyme activity into the solution, by as much as 20 minutes (data not shown).